INSTALLATION MANUAL - Jergens Inc.

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.2504TABLE OF CONTENTSGENERAL NOTES .................................................................................................... 30.0 INTRODUCTION .................................................................................................. 40.1 Operating personnel .......................................................................................... 40.2 Trained personnel ............................................................................................. 40.3 Individual protective equipment ......................................................................... 40.4 General safety instructions ................................................................................ 50.5 Behavior in emergency ..................................................................................... 50.6 Usage restrictions ............................................................................................. 50.7 Type plates ....................................................................................................... 61.0 TRANSPORT ....................................................................................................... 62.0 DESCRIPTION OF THE SYSTEM ....................................................................... 62.1 Structure of the Zero Point System (ZPS) ......................................................... 72.2 Circuit diagram of the Zero Point System (ZPS) ............................................... 82.3 Operation of the Zero Point System (ZPS) ........................................................ 83.0 INSTALLATION ................................................................................................... 93.1 General ............................................................................................................. 93.2 Installation in a mounting hole ......................................................................... 103.3 Removal from a mounting hole ....................................................................... 104.0 PULL STUDS ..................................................................................................... 114.1 Structure ......................................................................................................... 114.2 Installation Instructions .................................................................................... 124.3 Tolerances and pull stud arrangement ............................................................ 125.0 PERFORMANCE AND RESTRICTIONS ON USE ............................................ 135.1 Pull-in and locking force .................................................................................. 135.2 Holding force ................................................................................................... 135.3 Safety precautions .......................................................................................... 136.0 MAINTENANCE ................................................................................................. 136.1 Introduction ..................................................................................................... 136.2 Safety standards during maintenance ............................................................. 136.3 Daily Maintenance........................................................................................... 146.4 Monthly maintenance ...................................................................................... 146.5 Annual maintenance, but at the latest after 150,000 cycles ............................ 147.0 POSSIBLE PROBLEMS AND REMEDYING THEM ......................................... 148.0 DECOMMISSIONING AND DISPOSAL ............................................................ 148.1 Decommissioning ............................................................................................ 148.2 Storage ........................................................................................................... 148.3 Disposal .......................................................................................................... 14Jergens Workholding Solutions 877.426.2504 2 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.2504GENERAL NOTESThe present installation manual will assist you in becoming familiar with your new product. For thatreason we recommend that you read the documentation and carefully follow all instructions.For additional information we request that you contact Jergens Workholding Solutions Group at 877-426-2504THIS MANUALPlease consider this installation manual an important component of the delivered system. It should bewell taken care of during the entire time the system is in use.A copy of the present installation manual must be made available to the installation, operating andmaintenance personnel.Please ensure that all additional documents delivered are integrated into this manual. If your systemis transferred to a third party, we request that you also pass on this manualSTORAGE OF THE MANUALAlways handle this manual with care.It is not permissible to tear out pages or modify it.Please store these documents protected from heat and humidity.Jergens Inc., reserves the right to replace parts of the instructions contained herein at any time in thecourse of product improvement or if construction or commercial changes so demand, withoutimmediately providing a new edition.As the author of these instructions, Jergens Inc., forbids the reproduction in whole or even in part ofthese instructions, as well as any provision to third parties without written permission. Anymodification of the product requires permission of the manufacturer.Jergens Workholding Solutions 877.426.2504 3 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.25040. IntroductionCAUTION:The original configuration of this system may not be modified under any conditions.The use of this system for purposes other than those which the manufacturer intended can causeharm to the system or to the operator himself. Advance permission from the manufacturer must beobtained before machining materials other than those described in these instructions.Symbols usedMachining processes that represent a risk, or can cause injuries or harm tohealth if they are not properly performed.Machining processes that may only be performed by qualified specialistpersonnel. The possibility of residual risks cannot be ruled out.0.1 Operating personnelAs already mentioned above, certain operations may be performed exclusively by qualified or trainedpersonnel. The following standard features are used to describe the qualification level:Qualified personnel has sufficient technical knowledge or work experience to be able to recognize andprevent possible dangers (engineers and technicians).Trained personnel is appropriately instructed and/or monitored by qualified persons to be able torecognize the dangers and prevent them (personnel assigned to operation or maintenance). It musthave the following qualifications:1. Trained and authorized to operate the product safely and supply it with operating pressure orinterrupt the supply, and to mark it in accordance with the standard safety regulations.2. Trained in the correct procedure for maintenance and use of safety equipment in accordancewith the standard safety regulations.Before commissioning the equipment, the customer is obligated to make sure:1. Personnel has obtained, read and understood the installation manual;2. Personnel follows the instructions provided.0.2 Trained personnelMACHINE OPERATORS: Personnel based on appropriate instructions from the owner of the ZeroPoint System (ZPS), are assigned and authorized to operate it and connected devices. Anotherprerequisite is the complete knowledge and unlimited understanding of the contents of the presenthandbook.0.3 Individual protective equipmentThe personnel mentioned in the previous section must wear the appropriate protective clothingthat is required for the use of the working machine on which the Zero Point System (ZPS) isinstalled.Safety shoes are required, whereas the necessity of wearing hearing protectors, safety hats andsafety goggles must be judged by the operating company.The wearing of loose clothing that could become caught in the movable machine components isnot permitted.Jergens Workholding Solutions 877.426.2504 4 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.25040.4 General safety instructionsThe following regulations and recommendations correspond to the applicable legalregulations and are largely based on the observance of such safety regulations.JERGENS INC. is not liable for any harm to persons or property that can be traced back todisregarding the applicable safety regulations and/or the instructions contained in thepresent handbook. The respective most recent version of the installation manual isapplicable.All affected operators are therefore urged to follow and apply the instructions below andto strictly comply with the applicable accident protection regulations in the respectivecountry where the system is installed and used.All ordinary and extraordinary maintenance steps must be undertaken with the pressuresupply cut off.Before connecting the pressure it must be checked whether the operating pressure is inaccordance with the maximum allowable operating pressure.Transportation, installation, operation and ordinary or extraordinary maintenance of theZero Point System may be undertaken only by personnel meeting the requirementsmentioned in sections 0.1 and 0.2.0.5 Behavior in case of emergencyIt is recommended that the operating and maintenance instructions of the machine onwhich the Zero Point System is installed be applied in emergencies.In particular, measures must be taken so that no danger to persons or property can arisein case of a defect.In case of fire, take the designated extinguishing measures and take care that operatingpressure is no longer present.0.6 Restrictions on usageThe Zero Point system (ZPS) may be used solely for the uses specified in the installationmanual, and only in combination with the components recommended and approved byJERGENS INC.Allowed usage of the Zero Point System (ZPS): The ZPS is a spring-actuated single-actingclamping element that clamps a clamping plate or a workpiece pressure-free and self-locked with theZPS pull-stud. It is intended for installation and removal for machines or systems and may only beused within the scope of its technical data. The maximum loads and operating pressures specified bythe manufacturer must not be exceeded. All other types of use must be agreed with the manufacturer.The ZPS is suitable only to a limited extent in certain explosive environments. Further informationregarding this application is contained in separate installation instructions.Jergens Workholding Solutions 877.426.2504 5 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.25040.7 Type platesA label or the type plate of the manufacturer is affixed to the Zero PointSystem.CAUTION:Labels must not be removed under any conditions, even if the equipment is to be resold.Should the label be damaged or become detached, please contactJERGENS INC. to obtain a copy.In all communications with JERGENS INC. please always mention the model stamped onthe label.Disregarding these provisions releases JERGENS INC. from any liability for damage oraccidents caused thereby. In this case, the operating company is solely liable to theauthorities.1. TransportEvery Zero Point System (ZPS) is carefully tested before shipping. Upon receipt of the product,please check the integrity of the packaging and contents (subject to other instructions on the part ofJergens Inc.), to assure that the equipment was not damaged during transport and that the deliverycorresponds to the specification of the orderPlease report any defects or damage immediately to JERGENS INC. and the shipper who is liable forthe transport damage.CAUTION:Any defects or damage must be protested within 10 days of the receipt of the product.2. Description of the systemTechnical data sheet – Hydraulic version:Unit K5Pull-in and locking force in the[lbs] 1100system up toHolding force [lbs] 2900Maintenance after150,000....clamping cyclesMin. operating pressure [psi] 725Max. operating pressure [psi] 870Opening volume [in 3] .092Pre-positioning [in] .157Repeatability [in]

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.2504Technical data sheet – Pneumatic version:UnitK5Pull-in and locking force in the[lbs] 330system up toHolding force [lbs] 2900Maintenance after150,000....clamping cyclesMin. opening operating pressure [psi] 116Max. opening operating pressure [psi] 175Min. operating pressurefor retensioning[psi] 75Max. operating pressure[psi] 90for retensioningOpening volume [in 3 ] .092Pre-positioning [in] .157Repeatability [in]

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.2504Pneumatic version1. Ball2. Outside thread on cover3. Threaded stud (only for hydraulic version)4. Assembly tools preinstalled2.2 Circuit diagram of the Zero Point System (ZPS)Description of the required connections:Hydraulic version1 = Open hydraulicallyPneumatic version1 = Open pneumatically2 = Retension pneumatically2.3 Operation of the Zero Point System (ZPS)Vent: After installation of the hydraulic ZPS modules in a base, the entire system must be vented.Hydraulic versionOpening procedure:Pressurize ZPS.The ZPS will release the pull stud, enabling it to be moved in and out of the system.The ZPS will remain open as long as pressure is applied to the Open connection.Jergens Workholding Solutions 877.426.2504 8 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.2504Clamping procedure:Depressurize ZPS.The ZPS locks positively and is mechanically clamped by spring force. The ZPS will remainclosed as long as no pressure is applied to the Open connection. Pressure line can bedecoupled after the clamping process – the ZPS remains positively interlocked and self-locking.Pneumatic versionOpening procedure:Pressurize ZPS.Retensioning connection must be pressure-free.The ZPS will release the pull stud, enabling it to be moved in and out of the ZPS.The ZPS will remain open as long as pressure is applied to the Open connection.Clamping procedure:Depressurize ZPS.Pressurize retensioning connection briefly, then remove pressure.The ZPS is positively locked and mechanically clamped by spring force. The ZPS will remainclosed as long as no pressure is applied to the Open connection. Pressure line can bedecoupled after the clamping process – the ZPS remains positively interlocked and self-locking.Manual blow-out:The interior of the ZPS can be blown out with an ordinary commercialcompressed air blow gun or suctioned out with a vacuum device.During operation, there is danger of eye injury, since shavings can arisefrom the blow out.CAUTION: Wear safety goggles3. Installation3.1 GeneralSafety is only guaranteed if the Zero Point System (ZPS) is properly connected according toapplicable safety regulations.CAUTION:Only qualified personnel may connect the ZPS to the pressure supply.Follow the installation manual for the pressure intensifier in this regard.The spacing tolerances between the ZPS should not exceed +/- 0.01 mm. (0.00039”)Jergens Workholding Solutions 877.426.2504 9 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.2504The change pallet to be clamped with the integrated pull studs must always rest against the contactsurface of the ZPS base plate in the clamped state.3.2 Installation in a mounting holeDo not remove assembly tool for the hydraulic and pneumatic versionImportant:Neatly deburr mounting holes, clean hole and contact surface, check elements for greasedstateTilt-free introductionUniform screw tighteningof the Zero Point Systemwith installation tool, e.g.,face spannerCAUTION: The spring is pre-tensioned at installation.Uniform tightening up to flat contactof the cover on the support surface.Distance of cover from supportsurface of the base plate approx.0.2mmRemove installation tool andScrew threaded stud (hydraulicversion) with soluble and glue withthread locker for stainless steel intoZPS base.After installation, the bearings must be able to move freely in the track.Caution: Do not lift the base of the ZPS via the threaded stud. For this purpose, it can be screwedback again by one-half turn after contact with the bottom of the mounting hole.3.3 Removal from a mounting holeCAUTION:The system must be completely depressurized before starting the dismantling.Jergens Workholding Solutions 877.426.2504 10 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.2504Remove threaded stud (hydraulic version)Insert assembly tool CAUTION Spring is pre-tensioned in the installed state.Uniform unscrewing with installation tool, e.g.,face spannerUniform and tilt-free extractionNote on assembly tool : Screw long cylinder screw with large washer that covers the central holefor the pull stud into the base of the ZPS. In this way, the ZPS can be held together before removal sothat it can be taken out as a unit.The supply holes for the pressure medium must be free during removal, as otherwise a vacuum couldarise in the mounting hole.4. Pull Studs4.1 Structure1. Pallet to be changed2. Engagement nipple screw3. Pull StudJergens Workholding Solutions 877.426.2504 11 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.25044.2 Installation instructionsThe pull stud with the engagement screw is to be inserted into the provided hole of the pallet. Pleaseobserve the arrangement of the various stud shapes and the arrangement of the ZPS timing stud slit.Tighten engagement screw with the torque wrench and defined torque.K05: (M6) 14 Nm (10.3 ft. lbs)4.3 Tolerances and pull stud arrangementThe pull studs have the following designs:Zero-point stud (1)- for full centringTiming stud (2)- for the centering of the still-free axisClearance Stud (3)- only holding and tensioning functionBottom view of a change pallet with representation of the arrangement of the various pullstuds (drawing simplified):Note: The slit form of the timing stud must lie at an angle of 90° to the axis of connection between itand the zero-point stud.Distance tolerance:A = Zero-point to timing stud: +/- 0.01mm (0.00039”)B = Zero-point/timing stud to clearance stud: +/- 0.03mm (0.0011”)Jergens Workholding Solutions 877.426.2504 12 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.25045. PERFORMANCE AND RESTRICTIONS ON USE5.1 Pull-in and locking forceThe pull-in and locking force describes the force with which the stud is pulled in and clamped withpositive interlocking in the clamping module.5.2 Holding forceThe holding force specifies the maximum permissible axial pull force of the engagement screw. Asafety value suitable for the application must be additionally taken into consideration.Elevated tensile forces can cause a material-induced elastic deformation of the components.5.3 Safety precautionsSafety catch: An additional mechanical safety catch must be attached for vertical and horizontallysuspended clamping. For this usage, the user must consider a risk analysis of the forces occurringand then carry out an accident risk assessment in order to take appropriate protective measures.People are not permitted to be present in the danger zone.6. MAINTENANCE6.1 IntroductionAppropriate maintenance is important for a long service life of the systemand its components under flawless functional and operating conditions andadditionally guarantees the required operating safety over the long term.6.2 Safety standards during maintenanceCAUTION:All maintenance steps must be undertaken by qualified personnel (see chapter 0.1).Here are the most important points for the performance of maintenance measures:Maintenance and repair measures must be undertaken with a depressurized system. The entireoperating, maintenance and cleaning personnel must also strictly observe the applicableaccident prevention regulations in the country where the machine is installed.The ZPS is constantly under high spring pressure. Due to the pre-tensioning of the spring stack,serious, even life-threatening injuries can result from improper maintenance.Always wear safety shoes and all other required individual safety gear as well as clothing thatcovers the body as completely as possible. Do not wear any rings, watches, necklaces, braceletsor loose clothing.To guarantee flawless functionality, use only original replacement parts.Do not use abrasive or corrosive materials for cleaning the ZPS as they may impair the legibilityof the markings or type plates.Jergens Workholding Solutions 877.426.2504 13 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.25046.3 Daily maintenanceCheck the interior of the ZPS for contamination. It can be cleaned with an ordinary commercialcompressed air gun (wear safety goggles) or with a chip vacuum.6.4 Daily maintenance• Visual inspection of the condition of the ZPS• Checking the mounting screws and stud screws for firm seating• Removal of deposits on the module surface• Check for integrity and functioning of the system• Check of the pressure hoses or tubing• Check the oil level, change oil if needed6.5 Annual maintenance, but at the latest after 150,000 cyclesDismantling of the ZPS and renovation of the O-rings and the spring stack.Exchanging both elements is recommended as preventive repair.Preventive repair should be done at shorter intervals in case of very frequent clamping processes.The procedure for this should be coordinated with JERGENS INC.7. POSSIBLE PROBLEMS AND REMEDYING THEMThe information contained in this section supports the user in the identification of malfunctions thatcan occur during operation of the system.Malfunction Cause RemedyThe ZPS no longer openscompletelyVisible oil in the interior ofthe ZPS- Opening pressure is toolow- Oil level in the pressuregenerator- Check operating pressureat the pressure generatorand add oil if needed- Seals defective - Dismantle ZPS, replaceseals8. DECOMMISSIONING AND DISPOSAL8.1 DecommissioningIf the equipment is no longer going to be used, cut off the system from the pressure supply andremove it from the production machine on which it is installed.8.2 StorageThe following points should be considered:Clean and grease the surface of the zero-point system.Keep the system in a dry environment at +10° (50°F) ÷ 55°C (131°F).8.3 DisposalIf the ZPS unit will be scrapped, the oil in it must be emptied and disposed of in accordance with theapplicable legal regulations in the respective country.The remaining parts of the pump unit should be sorted by material and then also disposed of inaccordance with the legal regulations.Jergens Workholding Solutions 877.426.2504 14 | P age

INSTALLATION MANUALZPS- K5 CLAMPING MODULEworkholding@jergensinc.com877.426.2504www.jergensinc.com15700 South Waterloo RoadCleveland, OH 441101-877-426-2504workholding@jergensinc.comJergens Workholding Solutions 877.426.2504 15 | P age